Service Manual Instruction Manual
Table Of Contents
- Section A. Introduction - Maintenance Safety Precautions
- Section 1. Specifications
- Section 2. General
- Section 3. Chassis & Turntable
- 3.1 Tires And Wheels
- 3.2 Torque Hub
- Oil Information
- Roll and Leak Testing
- Tightening and Torquing Bolts
- Main Disassembly
- Output Carrier Disassembly
- Input Carrier Disassembly
- Hub-Spindle Disassembly
- Spindle-Brake Disassembly
- Cover Disassembly
- Cover Assembly
- Input Carrier Sub-Assembly
- Output Planet Gear Sub-Assembly
- Spindle - Brake Sub-Assembly
- Hub-Spindle Sub-Assembly
- Cover Sub-Assembly
- Main Assembly
- Integral Brake Check
- 3.3 Free Wheeling Option
- 3.4 Drive Motor
- 3.5 Oscillating Axle Bleeding Procedure and Lockout Test
- 3.6 Steer Adjustments
- 3.7 Swing Drive
- 3.8 Swing Bearing
- 3.9 Swing Brake - Mico
- 3.10 Rotary Coupling
- 3.11 Generator
- 3.12 Deutz D2.9 L4 Engine
- 3.13 Deutz D2011 Engine
- 3.14 Spark Arrester Cleaning Instructions
- 3.15 Glow Plugs
- 3.16 Deutz EMR 2
- 3.17 Bio Fuel in Deutz Engines
- 3.18 GM Engine General Maintenance
- 3.19 GM Engine Dual Fuel System
- Fuel Filter
- Direct Electronic Pressure Regulator (DEPR)
- Air Fuel Mixer
- Electronic Throttle Control (ETC)
- Electric Lock Off
- Engine Control Module (ECM)
- Heated Exhaust Gas Oxygen Sensor
- Gasoline Multi Point Fuel Injection System (MPFI)
- Gasoline Fuel Pump
- Gasoline Pressure And Temperature Sensor Manifold
- Fuel Filter
- Fuel Injector Rail
- Fuel Injector
- 3.20 GM Engine Fuel System Repair
- Propane Fuel System Pressure Relief
- Propane Fuel System Leak Test
- Propane Fuel Filter Replacement
- Direct Electronic Pressure Regulator (DEPR) Maintenance And Inspection
- Check/Drain Oil Build-Up In 2-Stage Vaporizer
- Air Fuel Mixer/Throttle Control Device Maintenance And Inspection
- Exhaust System And Catalytic Converter Inspection And Maintenance
- Temperature Manifold Absolute Pressure (TMAP) Sensor
- Throttle Body (ETC) Replacement
- Mixer Replacement
- Electronic Pressure Regulator (EPR) Replacement
- Regulator Replacement
- Coolant Hose Replacement
- Vapor Hose Replacement
- Engine Control Module Replacement
- Heated Exhaust Gas Oxygen Sensor Replacement
- 3.21 GM Engine LPG Fuel System Diagnosis
- Section 4. Boom & Platform
- Section 5. Hydraulics
- 5.1 O-Ring Lubrication
- 5.2 Cylinders - Theory of Operation
- 5.3 Cylinder Checking Procedure
- 5.4 Cylinder Removal and Installation
- Cylinder Locations
- Main Boom Telescope Cylinder Removal
- Main Boom Telescope Cylinder Installation
- Main Boom Lift Cylinder Removal
- Main Boom Lift Cylinder Installation
- Upright Level Cylinder Removal
- Upright Level Cylinder Installation
- Tower Boom Lift Cylinder Removal
- Tower Lift Cylinder Installation
- Tower Telescope Cylinder Removal
- Tower Telescope Cylinder Installation
- 5.5 Hydraulic Cylinder repair
- Tower Boom Lift Cylinder
- Cleaning and Inspection
- Assembly
- Upright Level Cylinder
- Cleaning and Inspection
- Assembly
- Master Cylinder
- Cleaning and Inspection
- Assembly
- Main Boom Lift Cylinder
- Cleaning and Inspection
- Assembly
- Main Boom Telescope Cylinder
- Cleaning and Inspection
- Assembly
- Tower Boom Telescope Cylinder
- Cleaning and Inspection
- Assembly
- Platform Level (Slave) Cylinder
- Cleaning and Inspection
- Assembly
- Jib Lift Cylinder (AJ Only)
- Cleaning and Inspection
- Assembly
- Steer Cylinder
- Cleaning and Inspection
- Assembly
- Axle Lockout Cylinder
- 5.6 Hydraulic Pump (Gear)
- 5.7 Variable Pump
- 5.8 Hydraulic Component Start-Up
- 5.9 Pressure Setting Procedures
- Section 6. JLG Control System
- Section 7. Basic Electrical Information & Schematics
SECTION 5 - HYDRAULICS
3121616 – JLG Lift – 5-69
Charge Pump
NOTE: Disassemble charge pump to inspect and clean, or change
auxiliary shaft drive coupling.
1. Remove auxiliary pump if necessary.
2. Remove screws retaining charge pump cover to pump
housing (Torx T). Seven screws are used with “no pad” or
SAE “A” auxiliary mounting pad charge pump cover, and
six screws are used with SAE “B” auxiliary mounting pad
charge pump cover. Remove charge pump cover, gas-
ket, and cover locating pins.
3. Remove gerotor cover assembly from charge pump
cover or back of pump housing. Remove gerotor cover
O-rings. Two O-rings are used on gerotor cover of all
pumps.
4. Remove gerotor assembly from gerotor cover or pump
housing.
5. Remove gerotor drive pin and drive coupling. Remove
gerotor cover locating pin from pump housing.
6. Inspect each part if they are to be reused. If either gerotor
assembly parts needs to be replaced, they must both be
replaced. Always replace O-rings and charge pump cover
gasket. Inspect journal bearing in gerotor cover for exces-
sive wear.
7. Lubricate gerotor assembly with clean hydraulic oil
before assembly.
8. Install gerotor drive pin into hole in drive coupling.
Apply grease or petroleum jelly to keep in place.
9. Install drive coupling on pump shaft with smaller out-
side diameter facing away from shaft.
10. Install gerotor assembly onto coupling.
11. Install gerotor cover locating pin into pump housing.
Install gerotor cover assembly over gerotor. Locating pin
must engage slot in gerotor cover.
NOTE: Charge pump rotation is determined by location of gerotor
recess and pressure balance hole in gerotor cover. Different
gerotor covers are used for clockwise and counterclockwise
rotation pumps.
12. Install new pressure balance O-rings to gerotor cover
and retain with petroleum jelly or grease.
13. Install charge pump cover locating pins and new charge
pump cover gasket.
14. Install charge pump cover. Cover must engage gerotor
cover and locating pins. Install charge pump cover
screws. Torque evenly to 26 - 32 ft-lb (36-43 Nm).
15. Reinstall auxiliary pump if necessary.
Figure 5-130. Charge Pump Components
1. Cover Retaining Screw 6. Gerotor Cover Locating Pin
2. O-Ring 7. Charge Pump Cover
Locating Pin
3. Gerotor Cover
4. Gerotor Assembly 8. Gerotor Drive Pin
5. Drive Coupling 9. Gasket